Attachment III - Technical Instructions
Front Brake Rotor Inspection/ReplacementTechnical Instructions
NOTE:
(Reference Taurus/Sable Shop Manual Section 12-20)
Front Brake Rotor - Inspection
1. Remove both front wheel and tire assemblies and inspect the rotors.
2. If the car is equipped with composite rotors on both sides or with one full-cast rotor and one composite rotor, both rotors must be replaced. Refer to the following removal and installation instructions (reference Taurus/Sable Shop Manual, Section 12-20 for the rotor replacement procedures).
3. If both front brake rotors are full-cast rotors, reinstall the wheels and tires and release the car. Claim 0.3 Hrs. under Labor Code A.
Front Brake Rotor - Removal
1. Remove wheel and tire assembly from rotor mounting face. Be careful to avoid damage or interference with caliper bleeder screw fitting and rotor splash shield.
2. Remove caliper assembly from rotor as follows:
a. Remove caliper locating pins using Torx Drive Bit D79P-2100-T40 or equivalent.
b. Lift caliper off rotor and integral knuckle and anchor plate using rotating motion.
CAUTION
Do not pry directly against plastic piston, or damage to piston will occur.
If caliper does not require servicing, it is not necessary to disconnect brake hose or remove caliper from vehicle. Position caliper out of the way and support it with a length of wire to avoid damaging the caliper and hose.
CAUTION
Handle caliper assembly in such a way as to prevent nicking, scratching or contamination of brake pad linings surfaces.
3. Remove rotor from hub assembly by pulling it off the hub studs.
If additional force is required to remove rotor, apply rust penetration on front and rear rotor/hub mating surfaces. Strike rotor between studs with a plastic hammer. If this does not work then attach a 3-Jaw Puller and remove rotor.
Front Brake Rotor - Installation
1. Before installing the new rotors, make sure rotor braking and mounting surfaces and hub mounting surfaces are clean from contaminants (eg. grease, oil, dirt, scale, etc.)
If required, to ease rotor installation, apply a small amount of Silicone Grease to pilot diameter of rotor.
2. Install rotor on hub assembly.
NOTE:
Replacement of front brake pads or overhaul of calipers is not covered by this recall and is considered the customer's routine maintenance responsibility. Normal grooving of brake pads does not necessitate replacement. Excessively worn pads (thin) may require replacement at owner's expense.
3. Install caliper assembly on rotor as follows:
a. Retract piston fully in piston bore. Position caliper assembly above rotor with anti-rattle spring under upper arm of knuckle. Install caliper over rotor with rotating motion. Be sure inner shoe is properly positioned.
The caliper bleed screw should be positioned on top of caliper when assembled on vehicle.
b. Lubricate locating pins and inside of insulators with silicone grease D7AZ-19A331-A or equivalent. Install locating pins through caliper insulators and into knuckle attaching holes.
NOTE:
The caliper locating pins must be inserted and threads started by hand.
c. Using Torx Drive Bit D79P-2100-T40 or equivalent, tighten caliper locating pins to 24-34 N-m (18-25 lb-ft).
4. Install wheel and tire assembly to rotor mounting face. Tighten wheel nuts to 109-142 N-m (80-105 lb-ft).
5. Pump brake pedal prior to moving vehicle to position brake pads.
6. Road test vehicle.
7. Mutilate and scrap both removed brake rotors.